Ballistic and impact protective system for military helmet assembly

ABSTRACT

A helmet assembly including a mandible bracket configured to connect a mandible to a helmet, with at least one strap connected to the mandible bracket and configured to extend from the mandible bracket to a helmet. The assembly includes at least one strap guide having a strap engaging portion connected to the strap along a length of the strap for connecting the strap to a helmet. The strap guide is removably attachable to the helmet, and in some embodiments the strap guide may be attached and/or removed through movement along a lengthwise direction of the strap, including in a horizontal direction. The assembly may secure an accessory other than a mandible to the helmet, and sufficient force on the accessory may remove the strap guide from the helmet.

RELATED APPLICATIONS

The present application is a continuation application of U.S.Non-Provisional patent application Ser. No. 14/115,759, filed Nov. 5,2013, and entitled “BALLISTIC AND IMPACT PROTECTIVE SYSTEM FOR MILITARYHELMET ASSEMBLY,” which is a national stage filing under 35 U.S.C. §371of International Patent Application No. PCT/US2012/036499, filed May 4,2012, and entitled “BALLISTIC AND IMPACT PROTECTIVE SYSTEM FOR MILITARYHELMET ASSEMBLY,” which is a continuation-in-part application of U.S.Non-Provisional patent application Ser. No. 13/101,320, filed May 5,2011, and entitled “BALLISTIC AND IMPACT PROTECTIVE SYSTEM FOR MILITARYHELMET ASSEMBLY,” which is a continuation-in-part application of U.S.Non-Provisional patent application Ser. No. 12/875,106, filed Sep. 2,2010, and entitled “BALLISTIC AND IMPACT PROTECTIVE SYSTEM FOR MILITARYHELMET ASSEMBLY,” which claims priority under 35 U.S.C. §119(e) to U.S.Provisional Patent Application Ser. No. 61/334,923, filed May 14, 2010,and entitled “BALLISTIC AND IMPACT PROTECTIVE VISOR SYSTEM FOR MILITARYHELMET ASSEMBLY,” U.S. Provisional Patent Application Ser. No.61/265,707, filed Dec. 1, 2009, and entitled “MULTI-COMPONENT HELMETASSEMBLY,” U.S. Provisional Patent Application Ser. No. 61/246,701,filed Sep. 29, 2009, and entitled “HELMET ASSEMBLY HAVING MULTIPLECOMPONENTS,” and U.S. Provisional Patent Application Ser. No.61/239,733, filed Sep. 3, 2009, and entitled “MULTI-COMPONENT HELMETASSEMBLY,” each of which is incorporated herein by reference itsentirety.

FIELD OF THE INVENTION

The present invention relates to helmet assemblies having multiplecomponents such as face shields, mandibles or mouth guards andaccessories for use on helmets.

BACKGROUND

Military and law-enforcement helmets with face shields are known such asdisclosed in U.S. Pat. Nos. 5,901,369 and 4,536,892. These face shieldsprovide pivot arrangements on opposite lateral sides of the face shieldto allow the face shield to be pivoted upward away from the user's facewhen the face shield is not deployed. The face shield is held in adeployed position in front of the user's face by locking of the pivotarrangements.

SUMMARY

The present inventors have recognized that it is desirable to provide ahelmet assembly with an improved attachment system for attaching a faceshield, a mandible, goggles and other accessories.

The present inventors have also recognized that it is desirable toprovide an attachment system that is quickly and easily installed onto,or removed from, a helmet.

The present inventors recognize the desirability of a mandibleattachment system for a helmet that is deployable with or without a sideand rear rail system.

An exemplary embodiment of the invention provides a helmet assembly thatincludes a mandible bracket configured to connect a mandible to ahelmet, with at least one strap connected to the mandible bracket andconfigured to extend from the mandible bracket to a rear portion of ahelmet. The assembly includes at least one strap guide having a strapengaging portion connected to the strap along a length of the strap forconnecting the strap to a helmet, and a fastener engaging portionconfigured to connect to a fastener attached to a helmet.

In one embodiment, the assembly has first and second strap connectorsconfigured to connect at a rear of a helmet. The assembly has first andsecond mandible brackets configured to connect the mandible to a helmet.The assembly has first and second straps. The first strap is connectedto the first mandible bracket at a first end of the first strap, and isconnected to the first strap connector at an opposite second end of thefirst strap. The second strap is connected to the second mandiblebracket at a first end of the second strap and is connected to thesecond strap connector at an opposite second end of the second strap.The assembly has first and second strap guides. The first strap guide isconnected to the first strap between the first mandible bracket and thefirst strap connector and is configured to be secured by a fastener to arear portion of a helmet. The second strap guide is connected to thesecond strap between the second mandible bracket and the second strapconnector and is configured to be secured by a fastener to a rearportion of a helmet.

In one embodiment the assembly includes a mandible and a mandible mountor front mount configured to be attached about a front opening of ahelmet. The mandible brackets are attached to opposite sides of themandible and connect the mandible to a helmet via the mount.

In one embodiment, the front mount comprises a mandible mountingchannel. The mandible bracket has a pin configured to be received in themounting channel to provide a pivotable connection of the mandible tothe helmet.

In one embodiment, the mandible has a deployed position about the user'smandibular region and a raised standby position providing access to auser's mouth. The straps have a connected position where the first strapconnector is attached to the second strap connector, and a releasedposition. The straps, when in the connected position, secure themandible in the deployed position.

In one embodiment, the fastener engaging portion of the strap guide hasa first channel having an open end opposite a closed end; and the strapholding portion comprises at least two strap slots configured to receivea strap. The strap slots are located on opposite sides of the firstchannel.

In one embodiment, the fastener engaging portion of the strap guidecomprises a first channel having an open end opposite a closed end.

In one embodiment, the first channel has at least one locking nublocated along a length of the channel between the open end and theclosed end to secure a portion of the fastener between the locking nuband the closed end.

In one embodiment, the fastener engaging portion of the strap guide hasan upper second channel located adjacent to the first channel. Thesecond channel has a width and length that is greater than the firstchannel. The second channel configured to receive the head of afastener.

In one embodiment, the strap holding portion of the strap guidecomprises at least two strap slots configured to receive the strapthrough the strap slots. The strap slots are located on opposite sidesof the first channel. The first channel is configured to be locatedunder a head of a fastener. The second channel is configured to engageat least a portion of the head of a fastener. The first and secondchannels are slide channels configured to slidably receive a fastenertherein.

An exemplary embodiment of the invention provides a method of securing aface protector, which maybe a mandible, to a helmet, comprising thesteps of, connecting a face protector about a front portion of thehelmet by face protector brackets, drawing straps from opposite sides ofthe face protector to the rear of the helmet, sliding at least one strapguide attached to each strap, on to a fastener attached to the helmet,connecting the straps together at a rear of the helmet.

In one embodiment, the step of connecting is performed before the stepof sliding. In one embodiment, the step of sliding is performed beforethe step of connecting.

In one embodiment, the step of sliding comprises the step of sliding achannel of the strap guide between the head of the fastener and thesurface of the helmet until the fastener is placed between at least onelocking nub of the channel and the closed end of the channel.

In some embodiments, an accessory attachment assembly for a helmetincludes at least one strap guide configured to connect a strap with ahelmet, with the strap guide having one of a fastener and a fastenerengaging portion for releasably receiving the other of a fastener and afastener engaging portion secured to a portion of a helmet. The strapguide further has a strap holding portion configured to hold a straprelative to the guide.

In some embodiments, an accessory attachment assembly for a helmet isprovided, with the assembly including at least one mandible bracketconfigured to connect a mandible to a helmet, and at least one strapconnected to the mandible bracket and configured to extend from themandible bracket to a rear portion of a helmet. The at least one strapguide has a strap engaging portion connected to the strap along a lengthof the strap, and a fastener or a fastener engaging portion configuredto connect to the other of a fastener or a fastener engaging portionthat is attached to a helmet.

In some embodiments, a method of securing a face protector to a helmetincludes connecting a face protector about a front portion of the helmetby face protector brackets, bringing straps connected to the faceprotector from opposite sides of the face protector to the rear of thehelmet, and sliding each of one or more strap guides onto a fastener orfastener engaging portion attached to the helmet. Each of the one ormore strap guides is attached to one of the straps. The method alsoincludes connecting the straps together, in some cases at a rear of thehelmet.

According to some embodiments, a method includes disconnecting aconnector which is connecting two strap portions of anaccessory-securing strap that is arranged to be mounted to a helmet. Themethod further includes exerting a force on an accessory that is beingsecured by the strap arrangement, and, through the exertion of force onthe accessory, disengaging at least one strap guide from the helmet, thestrap guide holding a strap portion of the two strap portions.

According to some embodiments, an accessory attachment assembly for ahelmet includes a strap to secure an accessory to a helmet, a firststrap guide holding the strap relative to the first strap guide, thefirst strap guide including a first engaging portion to engage with asecond engaging portion which is connected to the helmet. When the firststrap guide is attached to the helmet through the engagement of thefirst and second engaging portions, the assembly is constructed andarranged such that a force on the strap along a lengthwise direction ofthe strap and more than a threshold force disengages the first engagingportion from the second engaging portion.

An exemplary embodiment of the invention provides a helmet assembly thatincludes a face shield and the front mount is a center top mountingarrangement that operatively connects a center top location of the faceshield to a center front mount on the helmet. The face shield can beraised and lowered about a pivot axis provided in the mountingarrangement between a tilted up, non-use position and a lowered,deployed position. The mounting arrangement can include a detent and tworecesses, wherein the detent engages a first recess at a slightlyforwardly displaced position to allow ventilation between the helmet andmandible and the face shield and a second recess at the tilted up,non-use position. The recess and detent engagement can be overcome by aneasy manual force acting on the face shield to reposition the faceshield.

The exemplary embodiment provides a helmet attachment system thatattaches other devices such as goggle straps, night vision devices, andother devices. The exemplary embodiment of the present inventionprovides an attachment system that is quickly and easily installed ontoor removed from a helmet.

In one embodiment, the front mount or front rail may be substantiallycontiguous with side rails mounted to the helmet which extend rearwardfrom side edges of the front mount. The rear edges of the side rails canbe substantially contiguous with a back rail mounted on the helmet. Theside rails are configured to provide attachment locations for furthercomponents, such as lights, electronics, communication equipment, etc.

The combination of a front mount, side rails and back rail form asubstantially circumferential reinforcement of the helmet and providesfront side and rear mounting platforms for accessories, electronics andother tools and devices according to the needs of the wearer.

The mandible brackets or attachment bases may be arranged on a side ofthe helmet near to an ear covering of the helmet. The attachment baseseach include a metal base plate covered by an attached body block. Eachattachment base provides provisions for attaching one or more devices tothe attachment base, such as for attaching opposite ends of a mandibleto the bases. The metal base plate includes hooks for engaging an edgeof the helmet. A pair of strap assemblies is provided, each strapassembly connected to one attachment base. The mandible is screwed ontothe attachment bases. The mandible is easily installed by insertion of aheaded pin or rivet extending from each attachment base inward, throughchannels formed on the front mount or front rail and sliding theattachment bases with the mandible mounted thereto through the channeluntil the hooks engage the rim of the helmet. The straps are then drawnrearward and buckled.

The face shield mounting arrangement provides an effective, costefficient mechanism for holding the face shield in either the downwarddeployed position or the upwardly tilted, non-use position. A wearer canraise and lower the face shield with only one hand in some embodiments.This attribute allows a soldier to raise or lower his face shieldwithout putting down his rifle.

Advantageously, a front mount attached to the helmet can accommodateeither the face shield mounting arrangement or a night vision appliance.Thus the mounting apparatus for a helmet is simplified and the number ofparts and mounting complexities are reduced.

In one embodiment the face shield is a visor system that has a lens withoptics that are designed to provide not only impact protection but alsohigh energy ballistic protection while providing clarity by reducedrefractive power, astigmatism, and prism in the horizontal direction aswell as in the vertical direction. According to one embodiment the lenshas a thickness defined between the inner and outer surfaces. Thethickness is greatest at the centerpoint and tapers at a substantiallyconstant rate toward the edges. The radius of curvature of the outersurface of the lens is longer and offset forwardly of the radius ofcurvature of the inner surface of the lens causing the lens surfaces tobe eccentric.

Numerous other advantages and features of the present invention will bebecome readily apparent from the following detailed description ofembodiments of the invention, and from the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a helmet assembly outfitted with theattachment system of the present invention;

FIG. 2A is a left side view of the helmet assembly shown in FIG. 1;

FIG. 2B is a side view showing the helmet assembly with a face shield ina slightly tilted up position;

FIG. 2C is a side view showing the helmet assembly with the face shieldin a fully tilted up non-use position;

FIG. 2D is a perspective view showing the helmet assembly in a fullytilted up, non-use position;

FIG. 3 is a right side view of the helmet assembly shown in FIG. 1;

FIG. 4A is a rear view of the helmet assembly shown in FIG. 1;

FIG. 4B is a rear view identical to FIG. 4A but with portions removedfor explanation of underlying features;

FIG. 4C is a perspective view of the helmet assembly in an alternateconfiguration wherein the face shield is replaced by goggles;

FIG. 4D is a rear perspective view of the helmet assembly in analternate configuration wherein a top rail is added;

FIG. 4E is a right side perspective view of the helmet assembly of FIG.4D;

FIG. 5 is a bottom view of the helmet assembly shown in FIG. 1;

FIG. 6A is a left side perspective view of the helmet assembly shown inFIG. 1 with portions removed for explanation of underlying features;

FIG. 6B is a left side vide of the helmet assembly shown in FIG. 1 withportions removed for explanation of underlying features;

FIG. 6C is a left side vide of the helmet assembly shown in FIG. 1 withportions removed for explanation of underlying features and with theshock cord 10 channel cover shown transparent;

FIG. 7 is a right side perspective view of portions of the helmetassembly shown in FIG. 1 with portions removed for explanation ofunderlying features;

FIG. 8 is a front view of the helmet assembly portions shown in FIG. 7;

FIG. 9 is a rear perspective view of a face shield portion of theportion of the helmet assembly shown in FIG. 8;

FIG. 10A is an enlarged, fragmentary front perspective view of thehelmet assembly portion shown in FIG. 1 with portions removed forexplanation of underlying features;

FIG. 10B is a perspective view of a cap;

FIG. 10C is an enlarged, fragmentary front perspective view of thehelmet assembly portion with a second embodiment helmet mount;

FIG. 10D is a side view of the helmet assembly portion;

FIG. 10E is an enlarged, fragmentary front perspective view of thehelmet assembly portion with a second embodiment helmet mount;

FIG. 11 is a front perspective view of the face shield portion shown inFIG. 10A with portions of the face shield added;

FIG. 12 is a sectional view taken generally along line 12-12 of FIG. 11;

FIG. 13A is a front perspective view of the helmet assembly shown inFIG. 11 with portions removed for explanation of underlying features;

FIG. 13B is a perspective view of a portion of a mounting arrangementbaseplate;

FIG. 13C is a perspective view of the mounting arrangement with portionsremoved for explanation of underlying features;

FIG. 13D is a perspective view of the mounting arrangement with portionsremoved for explanation of underlying features;

FIG. 14 is a rear perspective view of a face shield assembly shown inFIG. 1 with portions removed for explanation of underlying features;

FIG. 15 is a front view of the face shield assembly shown in FIG. 14;

FIG. 16 is a left, rear perspective view of the helmet assembly shown inFIG. 1 with portions removed for explanation of underlying features;

FIG. 17 is a left side view of the helmet assembly shown in FIG. 16 withportions removed for explanation of underlying features;

FIG. 18 is a front perspective view of the helmet assembly of FIG. 1with portions removed for explanation of underlying features;

FIG. 19A is a front perspective view of the helmet assembly of FIG. 18with further portions removed for explanation of underlying features;

FIG. 19B is a perspective outside view of a side rail;

FIG. 20 is a front perspective view taken from of FIG. 1 with portionsremoved for explanation of underlying features showing a mandible;

FIG. 21 is a front perspective view taken from of FIG. 20 with portionsremoved for explanation of underlying features showing an underlyingtubular framework of the mandible;

FIG. 22 is a front perspective view taken from FIG. 1 with portionsremoved for explanation of underlying features showing a back rail;

FIG. 23 is a perspective view of a goggle strap clip shown in FIG. 22;

FIG. 24A is a perspective view of a helmet assembly with a mandible orlower jaw protection configuration;

FIG. 24B is a perspective view of a helmet assembly with a mandible orlower jaw protection configuration;

FIG. 24C is a perspective view of a helmet assembly with a mandible orlower jaw protection configuration;

FIG. 24D is a perspective view of a helmet assembly with a mandible orlower jaw protection configuration;

FIG. 24E is a perspective view of a helmet assembly with a mandible orlower jaw protection configuration;

FIG. 24F is a perspective view of a helmet assembly with a mandible orlower jaw protection configuration;

FIG. 24G is a perspective view of a helmet assembly with a mandible orlower jaw protection configuration;

FIG. 24H is a perspective view of a helmet assembly with a mandible orlower jaw protection configuration;

FIG. 25 is a perspective view of the face shield and mountingarrangement shown in FIG. 1, shown in a lowered, use position, butslightly open for ventilation, such as shown in FIG. 2B;

FIG. 26A is a sectional view taken generally along line 26-26 shown inFIG. 25;

FIG. 26B is a sectional view of a first embodiment of a pivot pin;

FIG. 26C is a sectional view of the first embodiment of a pivot pin witha ball;

FIG. 26D is a sectional view of a second embodiment of a pivot pin;

FIG. 26E is a sectional view of the second embodiment of a pivot pinwith a ball;

FIG. 27 is a perspective view of the face shield and mountingarrangement shown in FIG. 1 but shown in a raised, non-use position,such as shown in FIG. 2C;

FIG. 28 is a sectional view taken generally along line 28-28 shown inFIG. 27;

FIG. 29 is an enlarged, front perspective view of the lever for raisingthe face shield, shown in FIG. 1;

FIG. 30 is a rear perspective view of the lever shown in FIG. 29;

FIG. 31 is a rear view of the lever shown in FIG. 30;

FIG. 32 is a perspective view of an attachment base taken from FIG. 1;

FIG. 33 is a perspective view of the attachment base of FIG. 32 withportions removed for explanation of underlying features;

FIG. 34 is an inside perspective view of the attachment base shown inFIG. 33;

FIG. 35 is an enlarged fragmentary perspective view of a left side ofthe 20 helmet assembly;

FIG. 36 is an enlarged, fragmentary sectional view taken generally alongline 36-36 of FIG. 6A with an added functional attachment;

FIG. 37 is a perspective view of an alternate mandible attachmentsystem;

FIG. 38 is a fragmentary side view of a helmet with mandible using thealternate mandible attachment system of FIG. 37;

FIG. 39 is a fragmentary side view similar to FIG. 38 with portionsremoved to show underlying features;

FIG. 40A is a side view of the helmet assembly having a second alternateadjustable mandible attachment system;

FIG. 40B is a top view of the helmet assembly having a second alternateadjustable mandible attachment system;

FIG. 40C is an inside perspective view of the attachment base of thesecond alternate adjustable mandible attachment system;

FIG. 41 is a sectional side view taken along 41-41 from FIG. 40B withthe standoff mechanism in a lowered position;

FIG. 42 is a detailed view from FIG. 41;

FIG. 43 is a sectional side view from FIG. 40B generally along line 41-41, with the standoff mechanism in a raised position;

FIG. 44 is a detailed view from FIG. 43;

FIG. 45 is a rear view of the helmet assembly having an alternateadjustable back rail system;

FIG. 46 is a rear view of the helmet assembly having the alternateadjustable back rail system in a contracted position, where the helmetis not shown;

FIG. 47 is a rear view of the helmet assembly having the alternateadjustable back rail system in an expanded position, where the helmet isnot shown;

FIG. 48 is a fragmentary view of a portion of the center back rail andan outer rear rail of the adjustable back rail system;

FIG. 49 is a fragmentary view of a portion of the center back rail ofthe adjustable back rail system;

FIG. 50 is a sectional view taken from FIG. 48 generally along line50-50;

FIG. 51 is a section view taken from FIG. 48 generally along line 51-51;

FIG. 52 is a fragmentary view of a portion of the center back rail andan outer rear rail of an alternative toothed back rail embodiment of theadjustable back rail system;

FIG. 53 is a fragmentary view of a portion of the center back rail ofthe alternative toothed back rail embodiment of the adjustable back railsystem;

FIG. 54 is a sectional view from taken from FIG. 52 generally along line54-54;

FIG. 55 is a perspective front view of the center back rail of thetoothed back rail embodiment of the adjustable back rail system;

FIG. 56 is a perspective rear view of the center back rail of thetoothed back rail embodiment of the adjustable back rail system;

FIG. 57 is a second perspective front view of the center back rail ofthe toothed back rail embodiment of the adjustable back rail system;

FIG. 58 is a perspective view of a buckle member;

FIG. 59 is a perspective view of one embodiment of a lens of a visorsystem;

FIG. 60 is a front view of the lens of FIG. 59;

FIG. 61 is a horizontal cross-sectional view of the lens taken alongline 61-61 of FIG. 60 showing tapering thickness of the lens;

FIG. 62 is a vertical cross-sectional view of the lens taken along line62- 62 of FIG. 60;

FIG. 63 is side view of the lens of FIG. 59;

FIG. 64 is a perspective view of an alternative embodiment of a lens;

FIG. 65 is a front view of the lens of FIG. 64;

FIG. 66 is a top view of a lens positioned in front of a user; FIG. 67is a side view of a lens positioned in front of a user;

FIG. 68 is a perspective view of a head cap;

FIG. 69 is a perspective view of the helmet assembly having the headcap;

FIG. 70 is fragmentary perspective view of a helmet with one embodimentof a side rail;

FIG. 71 is a front perspective view of the second embodiment of the 20helmet mount;

FIG. 72 is an enlarged view of a portion of the second embodiment of thehelmet mount;

FIG. 73 is a rear perspective view of one embodiment of the helmetassembly showing an alternate embodiment mandible strap attachmentsystem;

FIG. 74 is a section view taken along line 74-74 of FIG. 73;

FIG. 75 is a perspective view of components of the alternate embodimentmandible strap attachment system of FIG. 73;

FIG. 76 is a side perspective view of components of the alternateembodiment mandible strap attachment system of FIG. 73;

FIG. 77 is a rear perspective view of the alternate embodiment mandiblestrap attachment system of FIG. 73;

FIG. 78 is a section view taken along the line 78-78 of FIG. 77;

FIG. 79 is a rear perspective view of the alternate embodiment mandiblestrap attachment system of FIG. 73;

FIG. 80 is a rear perspective view of a helmet having bolts and C-clipsinstalled;

FIG. 81 is a side perspective view of bolts and c-clips;

FIG. 82 is a section view taken along line 82-82 of FIG. 80;

FIG. 83 is a rear perspective view of a helmet embodiment including oneembodiment of a strap attachment system;

FIG. 84 is a rear perspective view of the embodiment of a strapattachment system shown in FIG. 83, with the strap guides attached tothe helmet;

FIG. 85 is a rear perspective view of the embodiment of a strapattachment system shown in FIGS. 83 and 84, with the strap guidesattached to the helmet and a connector engaged;

FIG. 86 is a top view of a strap guide according to one embodiment; and

FIG. 87 is a perspective view of the strap guide shown in FIG. 86.

DETAILED DESCRIPTION

While this invention is susceptible of embodiment in many differentforms, there are shown in the drawings, and will be described herein indetail, specific embodiments thereof with the understanding that thepresent disclosure is to be considered as an exemplification of theprinciples of the invention and is not intended to limit the inventionto the specific embodiments illustrated.

It should be noted that the helmet assembly described herein issymmetrical across a vertical, front-to-back centerplane as evidenced bythe figures and any description of a right side component will alsodescribe the left side component as a minor image thereof.

FIGS. 1-5 illustrate a helmet assembly 30 to be worn by a wearer 31(FIG. 3) according to an exemplary embodiment of the present invention.The helmet assembly includes a helmet, such as a military helmet 34. Amandible 36 is operatively connected to the helmet 34. A protective faceshield, such as a transparent visor or transparent face shield 38 isalso operatively connected to the helmet, substantially between a frontof the helmet 34 and the mandible 36. A mounting arrangement 42 isoperatively connected to the helmet 34 and to the face shield 38 whichallows movement of the face shield 38 with respect to the helmet. Themounting arrangement 42 includes a shield mount 43 and a helmet mount44.

The helmet mount 44 extends across at least a partial width of thehelmet and is contiguous on the right and left sides of the helmet to aleft side rail 46 and a right side rail 48 (left and right orientationsmentioned herein are according to the helmet wearer's perspective). Theside rails are minor image identical across a vertical, front-to-backcenter plane of the assembly 30. Rear portions of the rails 46, 48 arecontiguous with a back rail 52. The mount 44, the side rails 46, 48 andthe back rail 52 together substantially surround a perimeter of thehelmet 34.

The helmet mount includes two side channels 44 a, 44 b used for mountingthe mandible 36 as described below.

The helmet assembly can also be used with goggles 54 rather than theface shield 38, as shown in FIG. 4C. The goggles include straps 55 a, 55b that are connected to goggle clips to the back rail 52, as describedbelow. The back rail is design so that the back rail retains anunreleased goggle clip. In this way one the goggle clip and accompanyingstrap may be retained in the back rail even when the other goggle clipis released. This provides that a goggle may be quickly deployed byreattaching the released goggle a clip.

The mandible 36 is operatively mounted to the helmet 34 by left andright attachment bases 62, 64. For simplicity, only the left attachmentbase 62 will be describes as the right side attachment base is minorimage identical across the vertical, front-to-back center plane of theassembly.

The mandible 36 is fastened to the attachment base by two screws 71, 72.The attachment base 62 engages the helmet as described below and isdrawn rearward by a strap system 76. Only the left side strap system 76will be described but it is to be understood that a right side strapsystem 78 would be mirror image identical across the vertical,front-to-back center plane of the assembly. The front rail or mount 44,side rails and the back or rear rail provide support as a system for themandible.

The left side strap system includes a strap 82 that is connected by aloop 85 to the base 62 at one end and to a buckle member 87 at anopposite end. The buckle member 87 engages a buckle receiving slot 90formed in the back rail 52.

Face Shield and Mounting Arrangement

The details of the face shield 38 and the mounting arrangement 42 areshown in FIGS. 7-15 and 25-31.

The face shield 38 comprises a lens 94 and a frame 95. The lens 94 fitswithin a groove 97 (FIG. 9) in the frame 95 and is fixed to the frame bythree screws 96. For military use particularly, the face shield lens 94should be ballistic impact resistant. It can be of a laminatedconstruction and can feature a variable light transmission system. Sucha variable light transmission system can incorporate an electroniccontrol system to vary the light transmission according to the ambientlight conditions.

The face shield frame 95 is mounted to the mounting arrangement 42 viathe shield mount 43. The shield mount 43 comprises parallel lugs 98 a,98 b (FIG. 14). The lugs 98 a, 98 b include holes 99 a, 99 b forreceiving pins 99 c (only one shown, FIG. 13A). Each pins 99 c passesthrough a hole 101 (FIG. 12) formed through sides in a base portion 102(FIG. 11) of a lever 100, and are held in place by the head of the pinand a circlip or lock washer 99 d. The lever 100 includes a hole 103(FIG. 11) through a distal end thereof. A pivot pin 107 (FIG. 12) is fitthough the hole 103 and is fixed to sidewalls 110 a, 110 b (FIG. 13A)which extend outward from a baseplate 112. L-shaped side links 114 a,114 b are pinned at one end to the lugs 110 a, 110 b and at an oppositeend to the lugs 98 a, 98 b.

The lever 100 has a central recess 116 (FIGS. 11 and 12). An opening 118is provided within the central recess 116. A hook-shaped latch 122(FIGS. 11, 12 and 13A) has a base end pivotally attached to thesidewalls 110 a, 110 b by a through pin 124 (FIG. 12). The latch extendsoutwardly through the opening 118. The latch is biased to rotate upwardto a latched position by a torsion spring 130 (FIG. 13A). When the faceshield is moved from the upward, non-use position down to the deployedposition as shown in FIG. 1, the lever slides over the angular face 122a of the latch, which causes rotation of the latch downward as the hookend passes through the opening 118. Once the hook end of the 10 latch isthrough the opening 118, the latch rebounds by the urging of the torsionspring to rotate upward and the hook end overlies a first recessedsurface 116 a of the lever adjacent to the opening 118. The latch 122holds the lever 100 and the face shield 38 in the deployed position. Thelatch 122 can also be made to overlie a second recessed surface 116 b tohold the face shield in a slightly open position with respect to thehelmet and mandible. To move the face shield 38 to the slightly openposition or the tilted up, non-use position, the hook end 122 a of thelatch are depressed downward by a finger to release the latch from thelever and the face shield can be pivoted upward.

The pivot pin 107 is fixed to the sidewalls 110 a, 110 b by use of athreaded screw 123 a and a spring pin 123 b on each end of the pivot pin107 for each sidewall 110 a, 110 b. The spring pin 123 b is a pin havinga portion that is larger than a hole in the pivot pin 107 such that itis resiliently or deformable forced into the hole to hold the pivot pin107 fixedly to the side walls 110 a, 110 b. The use of a spring pinprevents unscrewing of the screw 123 a due to the repetitive raising andlowering of the face shield.

The pivot pin 107 includes two recesses 126 a, 126 b at two spacedapart, circumferential positions. A detent mechanism 127 is shown inFIGS. 26A and 28. The detent mechanism includes three spring mechanisms127 a arranged in parallel. Each mechanism includes a compression spring127 b that urges a ball 127 c toward the pivot pin 107. All thecompression springs are braced by a backing through pin 127 d. Thecompression spring 127 b and the ball 127 c are captured within acylindrical passage 100 a formed in the lever 100, by the backing pin127 d and the pivot pin 107. When installed, the springs 127 b arepre-compressed between the backing pin 127 d and the pivot pin 107 tothe degree necessary to allow the balls 127 c to be urged into theappropriate recess 126 a, 126 b when the recess presents itself to theballs 127 c upon rotation of the lever 100 with respect to the pivot pin107. The balls 127 c fit into the recess 126 a when the face shield ismoved slightly away from the helmet and mandible to allow for increasedventilation (FIG. 2B), and fit into the recess 126 b when the faceshield is pivoted into the raised, non-use position (FIGS. 2C and 20).The engagement between the detent mechanism 127 and either of therecesses 126 a, 126 b provides a resilient hold that can be overcome byforce from the wearers hand to pivot the face shield.

FIGS. 26A-26C show the first embodiment of the pivot pin 107. FIGS.26D-26E show the second embodiment of the pivot pin 108. The recesses126 a, 126 b of the first embodiment have a recess wall 126 c that has aconstant radius of curvature along its arc length. The first recess 126a is identical geometrically to the second recess 126 b. As shown inFIG. 26C, the constant radius of curvature allow the ball 127 c to fullycontact the recess along the entire recess wall.

The second embodiment of the pivot pin 108 provides a recess wall 108 c,108 d, 108 e that does not have a constant radius of curvature along itslength. In this configuration the ball 127 c does not make contact withthe recess along the entire recess wall as shown in FIG. 26E. The firstrecess 108 a is identical geometrically to the second recess 108 b.Referring to recess 108 b, the recess has two flat walls 108 c, 108 eare connected by a curved section 108 d. At least a portion of the flatwalls 108 c, 108 e contact the ball 127 c when it engages the recess 108b. This leaves a gap 108 h between the ball and at least a portion ofthe curved portion 108 d of the recess wall. The recess has full contactareas 108 g, 108 f and a non-contact area 108 k therebetween. Thearrangement prevents full contact between the ball and the entire lengthof the recess wall to reduce force needed to overcome the springpressure transferred to the ball. As less force is needed with thesecond embodiment of the pivot pin 108 as compared to the firstembodiment of the pivot pin 107, it is easier for a user to move themounting arrangement 42 between the deployed position and the standbyposition. In one embodiment, the contact area 108 g corresponds to theflat wall 108 e, and the contact area 108 f corresponds to the flat wall108 c, and the non-contact area 108 k corresponds to the curved section108 d.

The face shield is operable with one hand to raise and lower the faceshield. One finger depresses the latch 122 as the rest of the hand liftsthe face shield to a raised position. The face shield can be loweredwith one hand and the latch is self-engaging.

FIG. 13C shows the baseplate 112 includes a main body portion 132, abacking plate 133 (FIG. 13B), a spring 134, and a latching tongue 136.The main body portion 132 includes an upper edge 138 (FIGS. 9 and 12).The spring 134 biases the latching tongue 136 in a direction away fromthe upper edge 138. A handle 140 is connected to the latching tonguethrough a side clearance within the main body portion 132.

The backing plate 133 is a metal piece and includes side walls 133 ahaving holes 133 b which allow resin of the main body portion 132 toflow through the holes during overmolding to integrate the backing plate133 with the main body portion 132.

The mount 44 includes a top front formation or central accessory mount144 (FIG. 10) that includes an inverted U-shaped retainer portion 148,surface depressions 150, 152, 154, 156, 158, a top slot 160 and a bottomslot 162. The surface depressions 150-158 are sized and shaped toreceive protrusions 163, 164, 165, 166 (FIG. 9) on a back of thebaseplate 112.

The front mount is also compatible to mount a night vision appliance ornight vision goggle.

The front mount or front rail is mounted on the helmet using screws 360,362 and a center screw 363 (FIG. 10).

To mount the baseplate 112 to and into the formation 144, the top edge138 is fit into the top slot 160, the baseplate is fit snugly within theretainer portion 148 and the tongue 136 is retracted upwardly by forceon the handle 140 until the tongue can be fit into the bottom slot 162.

The mount side channels 44 a, 44 b each include a wide mouth 44 c and anarrow region 44 d (FIG. 6A). The side channels are used to mountmandible attachment bases as described below.

The face shield frame 95 can also incorporate a removable gasket to sealagainst the helmet brim to prevent ingress of fluids.

FIG. 14 shows the frame 95 includes frame supports 95 a that braceagainst the helmet gasket 240 when the face shield is properly seated.

A second embodiment of the mount or rail 1161 is shown in FIGS. 10B-10D.The mount 1161 includes a top front formation or central accessory mount1164 (FIG. 10B-10D) that includes an inverted U-shaped retainer portion1168, a surface depression 1166, lateral tabs 1168 a, 1168 b, a top slot1160 and a bottom slot 1162. The U-shaped retainer portion 1168 has sidewalls 1168 a, 1168 b, 1168 c. A recessed bottom edge 1168 d is oppositethe top side wall 1168 b. The surface depression 1166 and lateral tabs1168 a, 1168 b are sized and shaped to receive protrusions on a back ofthe accessory (not shown).

The helmet assembly may include a central accessory mount cap 45 asshown in FIG. 10B, 10D, and 10E. The cap forms a concavity on a backside. The concavity is defined by side walls 45 g, 45 h, 45 i, 45 j, topwalls 45 c, 45 d, 45 e, 45 f, an upper tab 45 a, and a lower tab. Theupper tab is positioned along the top side wall 45 h and the bottom tabis positioned along the bottom side wall 45 i. Opposite the top walls isan open side. The open side faces the top front formation or centralaccessory mount and is received thereon. The upper tab 45 a engages thetop slot 1160 of the central accessory mount. After the top tab is inlocation the cap is rotated downward in the direction G shown in FIG.100 so that the bottom tab engages the bottom slot 1162 of the centralaccessory mount. When the cap is secured over the central accessorymount a storage area is provided between the cap and the centralaccessory mount. The cap 45 may also be used on the central accessorymount 144 of the first embodiment of the 10 mount 44.

The second embodiment mount or rail 1161 is shown in FIG. 71. The railincludes two upper rail segments 1190, 1191 that flank the top frontformation or central accessory mount 1164. The rail also includes thebottom rail portion 1192 that extends under the upper rail segments1190, 1191 and under the top front formation or central accessory mount1164. Mounting apertures 1186, 1187 are located at opposed end areas ofthe rail. The mounting apertures allow that mount 1161 to be connectedto the front area of a helmet as shown in FIG. 10E. Also, mandiblesupport slots 1188, 1189 are provided at the opposite ends of the railand adjacent to the mounting apertures 1186 and 1187 respectively.Adjacent the mounting apertures on a side opposite the mandible supportslots are anchor receivers 1170, 1180. The right anchor receiver 1180 isminor image identical to the left anchor receiver across the verticalfront to back mid-plane of the helmet system as shown in FIG. 71.

The anchor receiver has a top recess, 1171, a bottom recess 1173, ananchor bar 1172, a vertical passage 1174, and a horizontal passage 1175.As shown in FIGS. 71 and 72, the anchor bar separates the top and bottomrecesses. The recesses have a back wall 1171 b, 1173 b, a first sidewall 1171 a, 1173 a, an opposite second side wall 1171 c, 1173 c. Thevertical passage 1174 extends behind the anchor bar 1172 verticallythrough to connect the top and bottom recesses. The horizontal recessextends from the back side of the anchor bar 1172 out the back of therail portion 1190.

A night vision device when mounted to the central accessory mount 1164may be stabilized by connecting one or more shock or elastic cords fromthe night vision device to the anchor receivers 1170, 1180. The anchorreceivers may be used to anchor a visor or any other accessory that ismounted to the central accessory mount 1164. The front anchor receiversare advantageous for, among other things, stabilizing the mountedaccessory when the front mount 1161 is used alone on a helmet, and sideand or back rails are not used.

Visor System

In one embodiment, the face shield 38 is a visor system 38. In oneembodiment, the visor system comprises the lens 94 and a frame 95. Inanother embodiment, the visor system comprises the lens 94, the frame95, the mounting arrangement 42, and a helmet mount 44.

Referring to FIGS. 59-63, in one embodiment the lens 94 has a top edge1136 that slopes downward from a top center point to first right andleft curve points 1134, 1133. At the first curve points the top edgebegins to slope more aggressively toward second right and left curvepoints 1134 a, 1133 a, and more aggressively toward right and left sideedge points 1132, 1131. On the left side, between the first curve point1133 and second curve point 1133 a is a top side beginning point 1133 b.The left side of the lens extends from the side beginning point 1133 bto the outermost point of the side edge 1131 to a bottom side beginningpoint 1141 (FIG. 63).

As is shown in FIG. 62, the plane of sight 1150 along the verticalextent of the lens is displaced above the plane 1151 intersecting theside edge points 1132, 1131. The plane of sight is thestraight-ahead-view plane of sight when the line of view is normal tothe internal surface of the lens. In one embodiment, the plane of sight1150 is located at the vertical mid-point on a lens blank that has notbeen cut into a particular shape.

A portion of the bottom edge extends from the bottom side beginningpoint 1141 along an outer bottom edge 1153 of the lens to a nose cutoutportion 1144. The bounds of the nose cutout portion 1144 are defined byopposite upward angled portions 1127 a, 1129 a that are connected by atop horizontal nose cutout portion 1121 a. The upward angled portions1127 a, 1129 a meet the outer bottom edge portions 1153, 1154 at bottomnose cutout corners 1127, 1129, respectively. The upward angled portions1127 a, 1129 a meet the top horizontal nose cutout border 1121 a at topnose cutout corners 1123, 1125, respectively. The nose cutout border1121 a has a midpoint 1121 that is coincident with the vertical midplane120 of the lens 94.

The vertical midplane 120 intersects a mounting hole 1138 that isconfigured to receive screw 96. The mounting hole is at least partiallylocated in a mounting protruding portion or tab 1140 of the lens. Themounting tab 1140 extends above the left and right top edges of the lens1128, 1130. The mounting tab is configured to be received in the frame95 and to securely engage the visor therewith. The lens 94 has athickness defined between the inner surface 1204 and the outer surface1202. In one embodiment, the lens is a tapering thickness lens. FIG. 61shows a cross sectional view taken along line 61-61 of FIG. 60, at 10the plane of sight. The outer surface 1202 is convex and the innersurface 1204 is concave. The outer surface 1202 has an outer surfaceradius of curvature RE originating at outer centerpoint of curvature CE.The inner surface 1204 has an inner surface radius of curvature RIoriginating at inner centerpoint of curvature CI. The surfaces 1202 and1204 have different radii of curvatures where the centerpoints of thoseradii are shifted relative to each other. In this embodiment, the innerradius RI is shorter than the outer radius RE. The thickness of the lenstapers from a centerpoint 1226 towards opposite left and right endpoints1225, 1227. The thickness of the lens is greatest at the midpoint to1226. In one embodiment, the thickness of the lens is the smallest atthe endpoints to 1225,1227. The thickness of the lens tapers at aconstant rate from the midpoint 1226 towards opposite endpoints 1225,1227.

The arc of the outer surface and the arc of the inner surface do nothave a common centerpoint. In one embodiment, the maximum arc 1214between a centerline 1205 and a reference ray 1216 extending from theinner centerpoint CI to the outer edge 1225 is 80 degrees. Therefore inthat embodiment, the arc of the lens extends for 160 degrees about innercenterpoint CI. In one embodiment, the thickness of the lens at themidpoint 1226 is greater than the distance between the centers ofcurvature CI and CE.

According to one embodiment, the thickness of the lens tapers at asubstantially constant rate from the thickest portion of the lens to theedges. The lens thickness may vary smoothly from the maximum thicknessat the center to the minimum thickness at or near the edges. The radiusRI may not be constant at the opposite left and right side ends of thelens, such as beyond 75 degrees from the center line 1205. Thisvariation area provides a minimum thickness at the edge. Moreover, thisvariation from the constant radius RI at the edges is allowable in somecases. It may be less important that the radius of curvature be constantat these end areas because this area is in the detection area of view ofa user and beyond the focusable field of view of the user. However, itis important to maintain a minimum thickness at the edges 1131, 1132 toprovide sufficient ballistic protection and impact protection.

According to the embodiment shown in FIG. 61, the tapering thicknesslens has the radii of the inner and outer surface offset from oneanother. The 20 centerpoint CE is offset forwardly from CI along thefrontal direction along Z axis as shown in FIG. 59. Correspondingly REis offset from RI in the frontal direction along Z axis. In oneembodiment, CI and CE are not offset vertically along the Y axis and arenot offset laterally in the horizontal plane along the X axis.

FIG. 61 shows a horizontal cross-sectional view of the taperingthickness lens that demonstrates a tapering lens thickness in thehorizontal direction. The lens tapers similarly in the verticaldirection. The lens has a vertical midpoint that comprises a maximumthickness and the lens tapers toward both a top edge 1136 and a bottomedge 1127 from the vertical midpoint.

According to one embodiment, the tapering thickness lens has an RI ofabout 104 mm, and an RE of about 106 mm, and the lens has a thickness atthe midpoint 1226 of about 5 mm. The lens has a radius of curvature inthe vertical direction along the inner surface of about 127 mm and aradius of curvature in the vertical direction along the outer surface ofabout 130 mm.

In another embodiment of the tapering thickness lens as shown in FIG.65, the radius RI is about 109 mm and the radius RE is about 111 mm andthe lens has a thickness at the midpoint 1226 of about 5 mm. The lenshas a radius of curvature in the vertical direction along the innersurface of about 127 mm and a radius of curvature in the verticaldirection along the outer surface of about 130 mm.

In one aspect, the lens has a minimum thickness of about 3 mm at thecenter 1226 in order to provide adequate impact protection and ballisticprotection. In another aspect, it has been found that a vertical radiusbetween 20 about 127 mm and about 130 mm with an about 5 mm centerthickness provides optics that reduce aberrations when the eyes arelooking upward and downward through the lens. Moreover the lens achievesimproved vertical field of view desirable for life-threateningsituations. Lenses having large vertical curvatures need to be taller,bigger, and/or heavier to make sure that the edges of the lens are notblocking the useful field of view in military operations. The lensaccording to certain embodiments of the invention avoids the problems oflarge vertical curvatures. Also, large vertical curvatures restrict theability to use the lens with ballistic mandible or jaw protectors, suchas mandible 36.

Tapering thickness lens with vertical curvatures in the range of about127 mm to about 130 mm have a desirable low-profiled design. Such lensprovides optics with low refractive power, low astigmatism, and lowprism power in both the horizontal and the vertical direction. The typeof lens is advantageous for soldier activities, such as inspecting theroof of buildings, crouching and looking upward to use a weapon,inspecting grounds and running. The tapering thickness lens providesoptics in the primary viewing area where the optical aberrations need tobe minimized for sharp precise vision. The primary viewing area extendsup to about 40 degrees sideways of eye rotation from the straight 15ahead viewing position in the horizontal direction and 40 degrees upwardand downward vertically from the straight ahead viewing position, eachof which is considered a limit where eye rotation stops and headrotation starts.

FIG. 66 demonstrates the horizontal extent of the primary viewing areaof the lens. A lens 94 is shown positioned in front of a user's eyes1401, 1402. The straight ahead line of sight 1403, 1404 from each eye isshown. Regarding the primary viewing area of the lens corresponding tothe right eye 1401, the primary viewing area extends forty degrees tothe right as shown by angle 1408 and forty degrees to the left as shownby angle 1410 Likewise, regarding the primary viewing area of the lenscorresponding to the left eye 1402, the primary viewing area extendsforty degrees to the right as shown by angle 1411 and forty degrees tothe left as shown by angle 1409. Therefore the lens has a primaryviewing area between the ray 1406 corresponding to forty degrees to theright of straight ahead view of the right eye 1401 and ray 1407corresponding to forty degrees to the left of straight ahead view of theleft eye 1402.

FIG. 67 demonstrates the vertical extent of the primary viewing area.The lens 94 is shown positioned in front of a user's eyes 1401, 1402.The straight ahead line of sight 1422 from for each eye is shown. Theprimary viewing area of the lens extends forty degrees upward as shownby the upward angle 1426. The primary viewing area of the lens extendsdownward forty degrees as shown by the downward angle 1425. Thereforethe vertical extent of the primary viewing area extends 80 degreesbetween the lower bound ray 1423 and the upper bound ray 1424. FIGS. 66and 67 show the extent of the primary viewing area when the lens ispositioned a distance from the user's eye of about 50 mm to about 60 mm,as for example positioned by mounting the lens to the helmet assembly 30and placing the lens in the deployed position in front of the user'seyes. In one embodiment, the lens is positioned a distance from theuser's eye of about 55 mm. One skilled in the art will recognize thatthe forgoing demonstrates a primary viewing area having a rectangle orsquare shape, but that the actual primary viewing area defined by thelimitations of a user's eye may be elliptical in shape as a user tendsto roll the eye downward or upward somewhat from the maximum upward ordownward position when the user turns the eye sideways while alsolooking up or down. Therefore, the actual primary viewing area of a usermay be slightly smaller than the primary viewing area of the lens.

In one embodiment, the tapering thickness lens has the following arclengths. The lens has a vertical arc length from bottom nose cutoutcorner 1127 following a vertical plane to a corresponding point 1124 onthe top edge 1128 is about 98 mm along the inner surface 1204 and isabout 103 mm along the outer surface 1202. The lens has a minimum centervertical arc length in the nose cutout portion from the top 1121 of thenose cutout portion 1144 to the top 1142 of the lens, excluding themounting tab 1140, of about 68 mm along the internal surface and about73 mm along the external surface. The lens has a maximum horizontal arclength from one side edge 1132 to the other 1131 of about 317 mm alongthe inner surface and about 331 mm along the outer surface. The nose cutout area has a maximum width from the first bottom nose cutout corner1127 to 15 the second bottom nose cutout corner 1129 of about 70 mm. Thenose cut out area has a minimum width at the top from 1123 to 1125 ofabout 35 mm. The lens has a top edge 1136 horizontal arc length from1133 b one side to the corresponding position on the other side of about224 mm along the inner surface and about 236 mm along the outer surface.The lens has an arc length along the lower edge and across the nosecutout area of about 266 mm along the inner surface and about 278 mmalong the outer surface. In one embodiment, the lens will have a minimumheight arc length of about 68 mm and a maximum height or vertical arclength of about 103 mm. The lens will have a minimum width or horizontalarc length of about 224 mm and a maximum width arc length of about 331mm.

FIGS. 64-65 show a tapering thickness lens 1301 of an alternativeembodiment. The lens 1301 conforms to the properties provided of thelens described in FIG. 61. The lens 1301 has a smaller nose cutout area1344 than that of lens 94. The lens 1301 may be used with a differentmandible than the mandible 36. Alternatively, it may be use without amandible.

In one embodiment, the tapering thickness lens of FIG. 64 has thefollowing arc lengths. The arc length of the lens 1301 from bottom nosecutout corner 1327 following a vertical plane to a corresponding point1324 on the top edge 1328 is about 78 mm along the inner surface and isabout 80 mm along the outer surface. The lens has a minimum centervertical arc length in the nose cutout portion from the top 1321 of thenose cutout portion 1344 to the top 1342 of the lens, excluding themounting tab 1340, of about 48 mm along the internal surface and about51 along the external surface. The lens has a maximum horizontal arclength from one side edge 1332 to the other 1331 of about 315 mm alongthe inner surface and about 337 mm along the outer surface. The nose cutout area has a maximum width from the first bottom nose cutout corner1327 to the second bottom nose cutout corner 1329 of about 38 mm. Thenose cut out area has a minimum width at the top from 1323 to 1325 ofabout 35 mm. The lens has a top edge 1336 horizontal arc length from1333 b one side to the corresponding position on the other side 1333 cof about 223 mm along the inner surface and about 241 mm along the outersurface. The lens has an arc length along the lower edge and across thenose cutout area of about 238 mm along the inner surface and about 266mm along the outer surface. In one embodiment, the lens will have aminimum height arc length of about 48 mm and a maximum height orvertical arc length of about 80 mm. The lens will have a minimum widthor horizontal arc length of about 223 mm and a maximum width arc lengthof about 337 mm.

While several arc length parameters are given, it will be appreciatedthat the invention is not limited to lenses of those arc lengths, butrather a tapering thickness lens having a horizontal radius of curvaturein the range of 100 mm to 10 120 mm, a vertical radius of curvature inthe range of 120 mm to 135 mm, and a maximum lens thickness in the rangeof about 5 mm to about 8 mm will accrue the advantages of embodiments ofthe invention including ballistic and impact protection while reducingrefractive power, astigmatism and prism in the horizontal direction aswell as in the vertical direction. Moreover, the lens may be used withor without a mandible or jaw protector. The lens may or may not have anose cutout portion such as 1144.

Mandible and Attachment

For military applications particularly, the mandible should be ballisticimpact resistant. The mandible could advantageously be used formotorcycle helmet, winter sport or auto racing applications. Themandible should have a high mass impact resistance.

FIG. 20-21 illustrates two embodiments of a mandible of the presentinvention. The mandible 36 shown in FIG. 20 is a unitary structure. Themandible includes an upstanding rim 259 that provides a surface againstwhich the lens 94 can be supported when closed.

The mandible 180 shown in FIG. 21 comprises a rigid material mandibleframe 180. The frame can be used alone to form a wire frame guard suchas shown in FIG. 24E, or can be covered by a ballistic resistant fabric182 as shown in FIG. 24F wherein the wire frame guard frame 180 is notvisible. The mandible frame 180 is a tubular space frame or wire framestructure to reduce weight.

The fabric 182 is attached to an outside of the frame 180 such as bywrapping around the frame and secured in place by hook and loopfasteners (VELCRO). In this way the fabric is removable. The frame 180includes two plates 183 a, 183 b which include holes for mounting themandible frame 180 to the attachment bases 62, 64 as described below.

As illustrated in FIGS. 18, 19A and 32-34, the attachment base 62comprises a base plate 230 and an overlying body block 232. The block232 can include a surface 232 a which can support ends of the faceshield frame 95 as shown in FIG. 1. The base plate 230 includes hooks234, 236 that engage a lower front edge 239 of a brim gasket 240 of thehelmet 34. The base plate 230 also includes two threaded bosses (orbosses terminating in captured nuts) 242, 244 that fit into holes 260,262 (FIGS. 19A, 20 and 21) through the mandible 36 or frame 180 andreceive screws 71, 72 that fasten together the mandible 36 (or frame180), the base plate 230 and the body block 232. The mandible providesholes 260, 262 that receive the bosses 242, 244 and screws 71, 72 (FIG.20).

The body block 232 includes a slot 263 that is engaged by the strap loop85 of the strap assembly 76.

As shown in FIG. 33, the base plate 230 also includes a fixed, headedpin or rivet 380 having a shaft 382 and a head 386.

As shown in FIGS. 16 and 17, the buckle member 87 includes a resilientlatch 320 that is depressed inwardly as the buckle member 87 is forcedinto the slot 90 of the back rail 52. The buckle member 87 also includesa base 324 that fits against a front surface 328 of the back rail. Thebuckle member also includes a plug portion 330 that fits snugly into asocket formation 334 contiguous with the slot 90.

To don the mandible or guard, the wearer moves the heads 386 of theheaded pins 380 of each attachment base 62, 64, with mandible 36 orframe 180 attached, into the wide mouth 44 c of the two side channels 44a, 44 b. As shown in FIG. 35, the wide mouth 44 c is wide enough toreceive the head 386 therein and the narrow region 44 d is wide enoughto allow sliding of the shaft 382 therethrough. Beneath the narrowregions 44 d is a parallel passage 44 e that is wide enough to allowsliding passage of the head 386. The attachment bases are slid downwarduntil the headed pins are stopped within the narrow regions 44 d. Themandible or frame and attachment bases are then rotated back and thehooks 234, 236 of the attachment bases will then be oriented to braceagainst the rim gasket 240 as the strap assemblies 76, 78 are strappedto the back rail 52 by the buckle members 87. To open the mandible forhydration (drinking), the buckle members 87 are released and themandible can be rotated forward without separating from the helmet dueto the headed pins 386.

Both the mandible hooks and the face shield frame supports rest againstthe helmet brim in the same area; should there be an impact, the loadshould be absorbed by the helmet.

Side Rails

The side rails 46, 48 are fastened to the helmet by screws 360, 362(FIGS. 1-3) at front ends of the side rails and by being engaged to theback rail at rear sides thereof. The screws 360, 362 also serve tofasten the front mount 44 to the helmet as well.

The side rails include an extending hook tab 370 (FIG. 19B) that fitsinto and interlocks with a hook recess 872 formed on opposite ends ofthe back rail (FIG. 22). When the back rail 52 is attached to the helmetthe rear ends of the side rails are fixedly clamped to the helmet viathe hook tabs 370.

As shown in FIGS. 6B and 6C, the side rails include integrated nightvision goggle (NVG) shock cords 47 b, one on each side which are used tostabilize and secure either the NVG or the face shield 38. Shock cordsare elastic cords. FIG. 6C shows a shock cord channel where the shockcord channel cover is transparent or not shown. Each side rail 46contains a shock cord channel 47 a that extends along a length of theside rail. The shock cord is anchored with an anchor 47 c that attachesthe cord at one end of the channel 47 a. The cord extends along thelength of the channel to the outlet 47 d. The outlet is widens beyondthe width of the channel as shown in FIG. 6B and 6C. The widened outletallow for a hook 47 e attached to the end of the cord to reset withinthe widened outlet when the cord is in the retracted position as shownin FIG. 6C. When an accessory needs to be stabilized with the shockcords, the user pulls and stretches the shock cord to an extendedcondition, such as shown FIG. 6B, and attaches it the accessory (notshown in FIGS. 6B, 6C).

The side rails 46, 48 include mounting formations 376, 377 (FIG. 4A) formounting an additional rail between the formations. FIG. 40A and 4Eillustrate a top rail 378 that includes legs 378 a, 378 b connected to atop pod or housing 379.

The formations include a guide recess 376 a and a slot 376 c (FIG. 16).To mount the top rail 378, the legs are engaged to the mountingformations wherein narrow end portions of the legs are inserted throughthe slots 378 c of each formation 376, 377. The distal end of each legincludes a hook latch 378 c that retains the legs 378 a, 378 b engagedwith the respective side rail 46, 48. The legs 378 a, 378 b can bearticulated at the pod 379 to act as latch tighteners to securely drawthe hook latches 378 c tightly against the slots 376 c.

Additionally, the slots 376 c can be made dimensionally identical to theslots 90 on the back rail 52. Therefore, if the top rail is not used,the wearer has alternate locations to insert the buckles 87 or can usethe slots 376 c for mounting another component.

The pod 379 is thus held onto a top region of the helmet 34. The pod 379can contain electronics, communication equipment, or other equipment orcan contain a beacon or other signal generating device which helps toidentify the wearer to others as “friend” instead of “foe”, or help inlocating the wearer by friendly forces. The signal generated by thebeacon can be a visual signal or radio signal or other signal. Where thesignal indicator is an IR designator, since it is emitting IR signals,it will be seen at night by other soldiers in the back of the helmetwearer, when the other soldiers wear night vision goggles.

FIGS. 6A and 36 illustrate the side rails 46, 48 include attachmentformations 46 a that include an upper and lower row of depressions 46 band a dovetail slot 46 c, between the rows of depressions. A componentattachment base 46 d includes a plurality of pins 46 f that insert intoa plurality of depressions. This insertion fixes the front-to-backposition of the base 46 d. The base 46 d includes a reverse dovetailprofile 46 g that interlocks with the dovetail slot 46 c. The dovetailprofile 46 g is slid into the dovetail slot and the pins 46 f and/or thebase 46 d and/or the rail 46 has sufficient flexibility that the basecan be forcibly positioned along the length of the rail until thedesired position of the base, corresponding to registration of the pins46 f into the desired depressions 46 b is reached.

The base 46 d can be the mounting base for a camera, flashlight or otherequipment.

Back Rail

Further details of the back rail 52 are illustrated in FIG. 22. The backrail 52 includes major openings 380, 382 having pie-shaped minorrecesses 380 a, 382 a contiguous therewith. Also shown are goggle clips386, 387 that engage recesses 380 a, 382 a by hook portions 386 a, 387a. The pie-shape of the recesses allows for a range of angular movementof the goggle clips with respect to the back rail 52. The back rail ismounted to the helmet by two screws 390, 392 (FIG. 4B).

The hook portions 386 a, 387 a allow one side of the goggles, one hookportion, to be released from the back rail 52 while the other hookportion retains the goggles, hanging down, onto the back rail. This isadvantageous for a wearer to disengage the goggles without separatingthe goggles from the remaining helmet equipment.

One clip 386 is shown in FIG. 23. The clip includes a body portion 386 bhaving slots 386 c, 386 d for receiving a goggle strap end, and formedwith the hook portion 386 a.

The back rail can also be configured to hold a power source such as abattery pack.

Adjustable Rear Rail System

FIGS. 45-51 illustrate an alternate embodiment of an adjustable backrail 852 that includes a first outer back rail 810, an opposite secondouter back rail 820, and a center back rail 830. The first and secondouter back rails are constructed in minor image fashion across avertical centerline of the helmet. The adjustable rear rail systemallows the parts of the helmet assembly 30 excluding the helmet, to beused on different sized helmets and will accommodate the variation inhelmet through hole location, which may arise for example during helmetmass production. The adjustable back rail system 852 is shown in anexpanded position in FIG. 47 and a retracted position in FIG. 46 foraccommodating different sized helmets. The adjustable back rail system852 may have an adjustable range beyond that shown in FIGS. 46 and 47.

As shown in FIG. 50, each outer back rail 810, 820 has a hook recess 872(not shown for outer rail 820). The extending hook tab 230 (FIG. 19B) ofthe side rails fit into and interlock with the hook recesses 872 of theouter back rails.

The center rear rail has U-shaped anchor slots 842, 844 (partially shownin FIG. 47). The anchor slots 842, 844 correspond to outer anchor slots812, 824, respectively of the first and second outer rear rails. Theanchor slots are at least partially alignable with the outer anchor slotfor receiving anchor screws (not shown, but similar to the screws 390,392) to secure the back rail system 852 to the helmet. In anotherembodiment the U-shaped anchor slots may be oblong, circular, or ovalshape.

The center back rail has an alignment point or line 836 for positioningthe center rear rail at the front-back center line of a helmet. Theouter back rails are positioned over outer ends 838 (second outer endnot shown) of the center back rail. The outer end 838 has two engagementtabs 839 a, 839 b extending laterally from an end of the center rearrail for engaging and sliding within corresponding receiving channels816, 818 of the outer back rail 810. Each engagement tab 839 a, 839 bhas a forwardly extending tab 839 c, 839 d, respectively. The forwardlyextending tabs correspond to forwardly extending recesses 816 c, 818 dof the receiving channels 816, 818, respectively.

When fitting the back rail system to the side rails and a helmet, thecenter back rail is aligned with the helmet at the alignment point 836.The side rails are attached to the outer rear rails. The outer rearrails are placed over the outer ends of the center back rail 830, andthe engagement tabs 839 a, 839 b mate with the receiving channels 816,818. Screws are then placed through the outer anchor slots 812, 824 andthrough the anchor slots 842, 844 to secure the back rail system to thehelmet.

In an alternative embodiment, toothed back rail embodiment of theadjustable back rail system, as shown in FIGS. 52-57, the outer ends 936(right outer end not shown) of the center back rail 930 has a pluralityof locking teeth on the outward facing surface throughout an engagementportion 938 of the outer end 936. The right outer end is minor imageidentical to the left outer end 936 across a vertical centerline of thehelmet. The center back rail 930 is similar to the center back rail 830except as described herein. The outer end 936 has two engagement tabs939 a, 939 b within the engagement portion 938. The two tabs 939 a, 939b form a U-shaped anchor slot 942 for receiving an anchor screw orfastener (not shown) to secure the back rail system to the helmet.

The outer back rails 910 have a corresponding toothed section 912 havinglocking teeth 914 on a rearward facing portion 916 of the outer backrail 910. Locking teeth 935 of the center back rail 930 engage thelocking teeth 914 of the outer back rail 910 when the outer back rail isplaced over the outer end of the center back rail. The toothedengagement between the center back rail and the outer back rails createa locked engagement when a screw or other fastener holds the outer backrail securely against the center back rail. When the a screw or fasteneris loosed the outer back rails may be adjusted laterally to accommodatedifferent sized helmets and/or accommodate the variation in helmetthrough hole location, which may arise for example during helmet massproduction.

In another embodiment, the tab engaging channel embodiment, as shown inFIGS. 48-51, is combined with the toothed back rail embodiment, as shownin FIGS. 52-57, so that outer ends 838 comprise a toothed engagementportion similar to the toothed engagement portion 938 while still havingengagement tabs like those of 839 a, 839 b with forwardly extending tabs839 c, 839 d, and the outer back rail 810, 820 comprising a rearwardfacing portion having teeth similar to the rearward facing portion 916while still having forwardly extending recesses like those of 816 c, 818d.

As shown in FIGS. 55-57, the center back rail 930 has slots 950, 960 forholding goggle straps and securing goggles against a user's face orhelmet. The center back rail 930 includes slots 950, 960 configured toreceive buckle members 970. The buckle member 970 includes a resilientlatch 972 that is depressed inwardly as the buckle member 970 is forcedin the direction F of FIG. 55 into the slot 960 of the back rail 930, ordirection E for the case of engaging slot 950. The buckle, as shown inFIG. 58, also has flanking supports 944 a, 974 b that are spaced apartin the lateral direction from the latch 972. The latch 976 has a firstraised area 977, and a second raised area 978 separated by a recessedarea 979.

The slots have a first raised portion 961 with lateral guiding segments962 a, 962 b on each lateral side. A gap 963 separates the first raisedportion from a main guide portion 962. Extending longitudinally inwardof the slot from the first raised portion 961 is a second raised portion964. The second raised portion 964 slopes upwards in a longitudinaldirection outward of the slot as it approaches the first raised portionto form a receiving area for receiving the second raised area 978 of thelatch 976. The buckle locks into the slot by the second raised area 978of the latch engaging the second raised portion 964 of the slot and therecessed area 979 of the latch engaging the first raised portion 961 ofthe slot, and the first raised area 977 of the latch engaged with anoutward facing surface 961 a of the first raised portion 961. Theflanking supports 974 a, 974 b are guided by the lateral guidingsegments 962 a, 962 b of the slot on one side and the main guide portion962 on the other when the buckle member enters and leaves the slot. Thebuckle member has a strap slot 972 for holding a strap at one end wherethe strap maybe connected to a goggle at the other end. It will beunderstood by one skilled in the art that in other embodiments, the backrail 52 or back rail 830 may comprise slots such as slot 950, 960 of theback rail 930, which are configured to receive buckle members 970.

Variations in Mandibles and Guards

FIGS. 24A-24H illustrate multiple variations of the mandible attached tothe helmet. FIG. 24A illustrates the mandible 36 previously describedmounted to the helmet 34. FIG. 24B illustrates a rigid guard 502 mountedto the helmet 34. The guard has a shorter profile than the rigidmandible. FIG. 240 illustrates a rigid guard 502 mounted to the helmet34 and carrying a removable ballistic resistant fabric 504 to extendprotection below the guard. FIG. 24D illustrates a rigid guard and anintegrated non-removable ballistic resistant fabric 508 mounted to thehelmet 34. FIG. 24E illustrates a rigid wireframe guard 180 mounted tothe helmet 34. FIG. 24 F illustrates the wireframe guard 180 (notvisible) having a ballistic resistant fabric 510 applied over the guard.FIG. 24G illustrates a lower semi-flexible frame 512. FIG. 24Hillustrates the lower semi-flexible frame 512 with a ballistic resistantfabric 516 to extend protection below the frame.

Semi flexible frame mandibles or guards provide the benefit ofconforming to a weapon when the wearer is aiming with a stock of theweapon proximate the cheek.

Alternate Mandible Attachment System

FIGS. 37-39 illustrate an alternate mandible attachment system thatincludes revised attachment bases 662, 664, constructed in minor imagefashion across a vertical centerplane of the helmet. The bases 662, 664include revised base plates 630, which are similar to the baseplates 230(FIGS. 33-34) except as described herein, and a revised helmet mount 644compared to the mount 44.

As illustrated in FIGS. 37-39, the attachment base 662 comprises a baseplate 630, and an overlying body block 632 (the block 632 is missing inthe attachment base 662 in FIG. 37 in order to see underlying features)similar in construction and attachment as the body block 232 shown inFIG. 32. The block 632 can include a surface 632 a which can supportends of the face shield frame 95 as shown in FIG. 1.

The base plate 630 includes a hook 234 that engage a lower front edge239 of a brim gasket 240 of the helmet 34 as previously described. Thebase plate 630 also includes an upstanding hook 636 having hookconcavities 636 a open forwardly.

The base plate 630 also includes two threaded bosses (or bossesterminating in captured nuts) 242, 244 that fit into holes 260, 262(FIGS. 19A, 20 and 21) through the mandible 36 or frame 180 and receivescrews 71, 72 that fasten together the mandible 36 (or frame 180), thebase plate 630 and the body block 632, as previously described. Themandible provides holes 260, 262 that receive the bosses 242, 244 andscrews 71, 72 as previously described (FIG. 20).

The body block 232 includes a slot 263 that is engaged by the strap loop85 of the strap assembly 76.

The mount 644 includes a concave area 644 a at each end thereof to forma shaped void 644 b between the mount 644 and the helmet 34, having anopen receiving slot 644 d.

The shaped void is partly defined by a hook- shaped support 644 c thathas a concavity open upwardly and rearward.

To don the mandible or guard, the wearer moves the upstanding hooks 636of each attachment base 662, 664, with mandible 36 or frame 180attached, into the open receiving slots 644 d of the two shaped voids644 b on opposite sides of the helmet. The relative position of themandible or frame with respect to the helmet is shown in FIG. 38. Asshown in FIG. 38-39, each void 644 b receives the hook concavity 636 ain mutual engagement with the hook-shaped support 644 c. After the hooks636 and the supports 644 c are engaged, the mandible or frame andattachment bases are then rotated down and back from the orientationshown in FIG. 38 to the orientation shown in

FIG. 39. The hooks 234 of the attachment bases 662, 664 will then beoriented to brace against the rim gasket 240 as the strap assemblies 76,78 are strapped to the back rail 52 by the buckle members 87 aspreviously described.

To open the mandible for hydration (drinking), the buckle members 87 arereleased and the mandible can be rotated forward. The degree ofengagement of the hooks 636 and the supports 644 c can be designed thatthe mandible or frame can be rotated sufficiently to hydrate withoutseparating from the helmet.

Both the mandible hooks and the face shield frame supports rest againstthe helmet brim in the same area; should there be an impact, the loadshould be absorbed by the helmet.

Mandible Adjustment System

FIGS. 40A-44 illustrate an alternative embodiment having a mandibleadjustment system that includes revised attachment bases 762, 764,constructed in minor image fashion across a vertical centerline of thehelmet. The second alternate adjustable mandible attachment systemprovides the ability to move the mandible between an upper limitposition, as for example shown in FIGS. 43 and 44, and a lower limitposition, as for example shown in FIGS. 41 and 43, to ensure optimalinterface between the bottom portion of the visor 94 and the mandible36. The adjustable mandible attachment system is adjustable to positionswithin a continuously variable range between the upper limit positionand the lower limit position.

The bases 762, 764 include revised base plates 730 as shown in FIG. 40C.The base plate 730 includes a fixed, headed pin or rivet 780. The bodyblock 732 includes a slot 763 that is engaged by the strap loop 85 ofthe strap assembly 76. The base plate includes a corresponding slot 763a for engaging the strap loop 85. The base plate 730 also includes twothreaded bosses (or bosses terminating in captured nuts) 742, 744 thatfit into holes 260, 262 (FIGS. 19A, 20 and 21) through the mandible 36or frame 180 and receive screws (not shown) that fasten together themandible 36 (or frame 180), the base plate 730 and the body block 732.

FIG. 40C also shows an inner plate 737 that mates with an inner side ofthe mandible to secure the mandible between the inner plate and the baseplate. The inner plate has two fastener holes 733 a, 733 b thatcorrespond to the threaded bosses 742, 744. The inner plate has aretainer 736 that engages the lower edge 239 of the brim gasket 240 ofthe helmet 34 (see FIG. 19A).

The base plate 730 has a standoff mechanism 791. The standoff mechanism791 has a contact plate 793, a base nut 795 and a set screw 797. Thecontact plate is flexible and is positioned between the lower edge 239of the brim gasket 240 of the helmet 34 (see FIG. 19A) or a lower edge734 of the helmet 34 and the set screw 797, as shown in FIG. 42. Thebase nut 795 is fixed to the inside surface of the base plate 730. Inone embodiment, the base nut 795 is located at a rearward position onthe base plate 730 near the slot 763. The contact plate prevents the setscrew from wearing on the lower edge of the helmet. The base nut isthreaded to receive threads of the set screw 797. The set screw has anAllen key (not shown) at the bottom 799 of the set screw, which isconfigured to receive an Allen wrench for turning the set screw. Otherturning mechanisms may also be employed.

As shown in FIG. 40C, the contact plate 793 has a T-shaped end 793 a.The opposite lateral ends of the T-shaped portion engage a contact plateslot 731 of the base plate on one side and a contact plate slot 736 c ofthe inner plate on the other side. The T-shaped portion holds theT-shaped portion of the contact plate in position between the base plateand the inner plate and the contact plate flexes from this location.

When the standoff mechanism is in the lowered position, as shown inFIGS. 41 and 42, the set screw is in a lowered position with respect tothe base nut. The base plate may rest against the top of the base nut,when the standoff mechanism is in the lowered position. When thestandoff mechanism is in the lowered positioned the mandible is in alowered position as shown in FIG. 41. To move the mandible upward theset screw is turned to raise the set screw relative to the base nut. Asthe set screw rises, it engages the contact plate 793 which putspressure on the lower edge of the helmet. As the set screw is movedupward relative to the base nut, the base plate 730 pivots about therivet 780 that is within the side channel 44 a, and thereby raises themandible closer to the front bottom edge of the helmet.

As shown in FIG. 44, the rear portion of the base plate is drivendownward as the set screw is moved upward relative to the base nut. Thiscauses the contact plate to flex, remaining connected to the base plateat one end and positioned between the set screw and the bottom edge ofthe helmet at an opposite end of the contact plate. The upper and lowerlimit positions are determined, at least in part, by the length of theset screw.

Protective Head Cap

As shown in FIGS. 68 and 69, the helmet system may include a protectivehead cap 1300. The cap has a front opening 1306 that corresponds to thetop front formation or central accessory mount 144. The centralaccessory mount may also be a mount for receiving the visor mountingarrangement 42. The front opening allows the accessory mount 144 to bereceived there through. The cap includes side rail engagement members1304 (not shown for right side). The left side rail engagement member1302 mirror image identical across the vertical midplate extending frontto back of the helmet system.

A second embodiment of the side rail 1310 is shown in FIG. 70. The sideraid is identical to the side rail 46 except as described. The rail 1310includes two raised portions 1314, 1316 and a recessed portion 1312therebetween. The raised portions have a plurality of first accessoryengagement recesses 1308, 1309 Similar first accessory engagementrecesses 46 f, 46 g are shown in rail 46 in FIG. 6. The recessed portioncontains a plurality of second accessory engagement recesses. The secondengagement recesses are larger than the first engagement recessed. Theengagement recesses can be used to secure accessories to the side rail.

The side rail engagement members 1302 contain an attachment mechanismfor securing the protective cap to the side rails of the helmet systemas shown in FIG. 69. The attachment mechanisms may comprise flexibleprotrusion on the underside of the side rail 1302 or an upper portion ofthe side rail 1304. The flexible protrusions engage one or more ofcorresponding second or first engagement recesses 1311, 1308 of the rail1310. The flexible protrusion secure the cap 1300 to the side railsuntil a predetermined amount of force is applied in the H direction, asshown in FIG. 69, to remove the cap from the side rails.

Alternatively the cap 1300 may have an attachment mechanism havingengagement members that are manually releasable by a mechanical lockingmechanism. The engagement member engages the second or first engagementrecesses 1311, 1308. The cap is removable by releasing the mechanicallocking mechanism. The attachment mechanism may provide a slidingone-way lock engagement that allows the cap to be slid on in thedirection F as shown in FIG. 68, but not removed without the release ofthe lock mechanism. In another embodiment, the lock mechanisms by beelectronically controlled.

The cap 1300 may be made of composite material such as KEVLAR andthermoplastic or High-density polyethylene and thermoplastic.

Alternate Embodiment Mandible Strap Attachment System

FIGS. 73-82 show various components of an alternate embodiment mandiblestrap attachment system 1230. The alternate mandible strap attachmentsystem 1230 allows a mandible to be used with the helmet assembly when arear rail, such as rail 52 or 930 is not used. The alternate mandiblestrap attachment system 1230 also allows a mandible to be used when siderails 46, 48 and a rear rail 52, 930 are both not used, such as whenmount 1164 is used.

The mandible strap attachment system 1230 comprises a left mandiblestrap 1240, a right mandible strap 1246, a left strap guide 1260, andright strap guide 1262, a female strap connector 1250, a male strapconnector 1252, a left mounting bolt or fastener 1270, a right mountingbolt or fastener 1272, a C-clip 1280. Each of the left and right sidestraps 1240, 1246 have a mandible attachment end 1242 (not shown forright side) and an opposite connector end 1244, 1248 respectively. Thebody block 232 of the attachment base 62 includes the slot 263 that isengaged by the strap loop 1242 of the left mandible strap 1240. Theright side strap connects to the attachment base 64 in a minor imageidentical fashion across the vertical, front-to-back center plane of theassembly. The connector end 1244 is attached to a strap bar 1250 c ofthe female strap connector 1250. The female strap connector 1250 has anopening 1250 d opposite the strap bar for receiving the male strapconnector 1252. The female strap connector 1250 has upper and loweropenings 1250 a, 1250 b for releasably receiving flexible expandingtongs 1252 a, 1252 b respectively of the male strap connector 1252. Theconnector end 1248 is attached to the strap bar 1250 c of the male strapconnector 1250.

Before the straps 1240, 1246 are connected to either the attachment baseor the strap connector or both, the strap is fed through thecorresponding left mandible guide or right mandible guide. The strapguides 1260, 1262 are shown in detail in FIGS. 75 and 78 Referring tostrap guide 1260, the guide has a first strap slot 1263 opposite asecond strap slot 1264. The strap slots extend vertically on oppositesides of the guide. The strap slots are sized large enough to receivethe width of strap 1240. Between the strap slots are a head receivingU-shaped channel 1265 and lower U-shaped channel 1266. Both U-shapedchannels create an open bottom so that the strap slots are held togetherat the top section 1267. The head receiving U-shaped channel 1265 issized to receive a head 1273 of the bolts 1270, 1272. The lower U-shapedchannel is sized to receive a transition region 1274, a washer 1279located around a shaft 1275, or a shaft 1275 of the bolts 1270, 1272. Inone embodiment, the lower U-shaped channel is sized to receive atransition region 1274 or the washer 1279 located around the shaft 1275.The width of the lower U-shaped channel 1266 is less than the width ofthe head receiving U-shaped channel 1265 so that the head is not allowedto pass below the lower U-shaped channel 1266.

Referring to FIG. 75, the lower U-shaped channel 1266 has opposite sidewalls 1266 a, 1266 b. Each side wall has locking nubs 1269 (not shownfor right side wall) located along its length so that the transitionregion 1274, the washer 1279, or another part of the bolt 1270 may besecured in the channel between the locking nubs and the closed end wall1266 c. The locking nub not shown for the right side wall 1266 b ispositioned along the length of the channel 1266 the same distance fromthe open end 1266 d of the channel as locking nub 1269 on the oppositeside wall 1266 a is located from the open end 1266 d. The bolt may bemoved further into the channel 1266 by sufficient hand-applied force tothe strap guide to cause the channel 1266 to flex outward slightly toallow the bolt to move past the locking nub and to be held between thelocking nub and the end 1266 c of the channel. In one embodiment, thechannel 1266 has a narrowing width along at least a portion of thechannel between the open end 1266 d and the closed end 1266 c to providean increasing friction engagement with the transition region 1274 or thewasher 1279.

Referring to FIG. 78, the strap guide 1260 receives the bolt head in anat least partially recess fashion within the head receiving U-shapedchannel 1265 relative to the strap slots so that the strap can bethreaded through the strap slots 1263, 1264 and over the bolt head 1273.In this way, the strap guides direct the strap in close proximity to thehelmet and guide them towards their connection at the rear of the helmetvia the strap connectors 1250, 1252 above the lower edge of the helmet.

Referring to FIG. 76, the system may be used with at least two types ofbolts 1270, 1276 for mounting the strap guides 1260, 1262. One bolt is astep bolt 1270, 1272.

The step bolt has a head 1273, and a transition region 1274 extendingbetween the head and a shaft 1275 below the head. The step bolt has thetransition region 1274 permanently connected adjacent the underside ofthe head 1273. Alternatively, a shaft only bolt 1276 may be used havinga head 1277 connected to a shaft wherein a washer 1279 is fit over theshaft slid up against the bottom side of the bolt head and configured toengage the lower U-shaped channel 1266 of the guides 1260, 1262.

The mounting bolts 1270, 1272 may be located in helmet threaded holeslocated laterally in the helmet between the front to back midplane 34 aat the rear and the ear cups 34 b as shown in FIG. 73. FIG. 79 shows thestrap attachment system in the engaged mode providing stabilizing forcefor the attachment bases.

When the strap guides 1260, 1262 are not in use, a c-clip 1280 may beused with the bolts 1270, 1272 to reduce the chance that anything issnagged on the head of the bolt as shown in FIGS. 80-82. A C-clip has aninside surface 1282 and a first angled surface 1381 that may contact thetransition of the bolt or the washer. Extending out from the insidesurface 1282 is the first substantially horizontal surface 1281 adjacentan opposite declining surface 1283.

Once the fasteners 1270, 1272 are set to a proper depth in the helmet,the strap guides 1260, 1262 may be engaged with the helmet by slidingthe strap guides down in the direction 1290 shown in FIG. 73 until theyare secured such as shown in FIG. 79 where the bolts are seated againstthe closed end 1266 of the channel or in close proximity to the closedend of the channel. Tension on the strap tends to keep the strap guidesengaged and down against the bolts. The strap guides can be removed bymoving them in the direction opposite of direction 1290 in FIG. 73.

The mandible 36 can be removed by unbuckling the straps 1240, 1246,removing the strap guides 1260, 1262 from the fasteners bolts, andsliding the headed pins of the attachment bases 62, 64 up out of thechannels formed in the front mount or front rail 44, 1164.

According to further embodiments, a single or dual motion accessoryremoval method may be facilitated by a strap guide arrangement. Strapguides 1260, 1262 are shown engaging with bolts 1270, 1272 via movementin a vertical direction. In some embodiments, straps guides may beprovided which attach to and detach from the helmet through movement ina direction other than vertical. For example, referring to FIGS. 83-87,in some embodiments one more strap guides 1560, 1562 may be engaged to,and/or disengaged from, bolts 1270, 1272 through horizontal movement.

Strap guides 1560, 1562 are shown in FIG. 83 unattached to bolts 1270,1272. The strap guides are moved horizontally to engage with bolts 1270,1272. For example, strap guide 1560 is moved to the right in thedirection of arrow 1584 to engage with bolt 1270. Once each strap guidehas been engaged with its respective bolt, female strap connector 1250and male strap connector 1252 may be engaged as described above tosecure an accessory, such as a mandible, to the helmet.

To remove the strap from the helmet, and consequently also remove theaccessory from the helmet, straps guides 1560, 1562 may be arranged suchthat a horizontal force on the strap guides equal to or greater than athreshold force disengages the strap guides from the bolts or otherfasteners. For example, a user may directly grip the strap guide(s) andpush or pull the strap guide(s) horizontally to remove each strap guidefrom its respective bolt. Another manner of disengaging the strap guidesincludes the user pulling the mandible (or other accessory), whichtensions the strap and pulls on the strap guide(s). The resulting forceon the strap guides pulls the strap guides 1560, 1562 off of their bolts1270, 1272. In this manner, the user can remove one or both strap guideswith a single motion. In the particular arrangement shown in FIGS.83-85, the single motion is a pulling motion of the accessory away fromthe face, but other motions could be used in other embodiments.

In this embodiment, the user can thus remove an accessory with only twoactions, namely disconnecting a connector and pulling on the accessory,while still taking advantage of the utility of two strap guides. Inother embodiments, the user can remove an accessory with two actionswhich may differ from the two actions of this embodiments. For example,after disconnecting a connector, instead of pulling on an accessory, theuser may push on a portion of the accessory, which in turn through alever action pulls on a strap. Of course, other embodiments may includeaccessory removal methods which include more than two actions.

One embodiment of strap guide 1562 is shown in FIGS. 86 and 87. Similarto the strap guide embodiment illustrated in FIG. 75, strap guide 1562includes a head receiving U-shaped channel 1565 and a lower U-shapedchannel 1566. Different from the embodiment shown in FIG. 75, however,is that strap guide 1562 is arranged such that the lengthwise directionof the strap travels in the direction of the U-shaped channels. In thismanner, tension on the strap can pull strap guide 1562 off of acorresponding engaging portion, such as a bolt, that is affixed to thehelmet.

Strap guide 1562 has a first strap slot 1563 and a second strap slot1564. The strap slots are sized to receive the width of strap 1246. Insome embodiments, the head receiving U-shaped channel 1565 is sized toreceive an upper portion of a fastener. For example, referring to FIG.78, head receiving U-shaped channel 1565 may be configured to receive ahead 1273 of a bolt. The lower U-shaped channel 1566 may be constructedand arranged to receive another part of a fastener. For example,referring again to FIG. 78, the lower U-shaped channel may be configuredto receive a shaft 1275 of the bolt, a transition region 1274, or awasher 1279 located around the shaft 1275. The width of the lowerU-shaped channel 1566 may be less than the width of the head receivingU-shaped channel 1565 so that the head is prevented from passing belowthe lower U-shaped channel.

Locking nubs 1569 may be provided to restrain the part of the bolt orother fastener that is held within lower U-shaped channel 1566 betweenthe nubs 1569 and an end wall 1566 c. Accordingly, when a user pulls onthe strap or the slide clip to remove slide clip 1562 from itsassociated fastener, at least a threshold force is applied to overcomethe resistance of the nubs 1569 before the slide clip disengages fromthe fastener.

In various embodiments disclosed herein, strap guides are described ashaving channels or other fastener engaging portions which engage withfasteners that are attached to a helmet. In some embodiments, thesefeatures may be reversed such that structures having fastener engagingportions (such as channels) may be affixed to a helmet, and theassociated strap guides may include fasteners such as bolts or shafts.

Grip protrusions 1580 may be provided on one or both sides of slide clip1562 to facilitate gripping of the slide clip when directly engaging ordisengaging the slide clip with its associated fastener. The protrusions1580 may be especially helpful when the user is wearing gloves. Othergrip features such as a textured material or a textured material finishon the slide grip may be provided.

In other embodiments, strap guides may be moved in a diagonal directionto engage with bolts, posts or other fasteners. Movement in anengagement direction also may include a first movement in a firstdirection and a second movement in a second direction. For example, astrap guide may be moved horizontally to initially engage with a boltthat is fixed to the helmet, and then moved vertically to complete theengagement.

In still further embodiments, a strap attachment system may be arrangedsuch that straps are oriented vertically or diagonally on a helmet, andtension on the strap in a lengthwise direction of the strap disengagesthe strap guide(s) from the helmet.

While embodiments disclosed herein illustrate the securement of amandible to a helmet through the use of a strap attachment system, thesystems and methods described herein may be used with accessories otherthan mandibles.

Exemplary materials of construction for the various embodiments of thehelmet assembly include:

Helmet: Aramid fiber textile with either thermoplastic matrix orthermoset matrix

Front mount: Glass reinforced nylon for the plastic part and Aluminumfor the insert (where the visor attaches/anchors) Side rails: Glassreinforced nylon

Back Rail: Glass reinforced nylon

Top rail: Glass reinforced nylon

Attachment bases for mandible: Glass reinforced nylon over Aluminum,Steel, Stainless Steel or Titanium

Rigid mandible: It can be a combination of various materials such as: 1)aramid fiber textile and thermoplastic or thermoset matrix 2) aramidfiber textile and thermoplastic or thermoset matrix wrapped in carbonfiber textile 3) High Density Polyethylene wrapped in carbon fibertextile Soft mandible: Semi-Flexible Frame made of Nylon while thecurtain (hanging from the frame) is made out of aramid fiber textile(many layers).

The presently described embodiments provides flexibility in outfitting amilitary helmet. The back rail can be used without the side rails. A toprail is optional. The mandible or frame is optional, and when used, canbe used without the side rails. Other permutations are possible withsome minor modifications.

From the foregoing, it will be observed that numerous variations andmodifications may be effected without departing from the spirit andscope of the invention. It is to be understood that no limitation withrespect to the specific apparatus illustrated herein is intended orshould be inferred.

What is claimed is:
 1. An accessory attachment assembly for a helmet,comprising: at least one strap guide configured to connect a strap witha helmet; the strap guide having a fastener engaging portion forreleasably receiving a fastener secured to a rear portion of a helmet,and a strap holding portion configured to hold a strap relative to theguide.
 2. The accessory attachment assembly of claim 1, wherein thefastener engaging portion comprises a first channel having an open endopposite a closed end.
 3. The accessory attachment assembly of claim 2,wherein the first channel has at least one locking nub located along alength of the channel between the open end and the closed end to securea portion of the fastener between the locking nub and the closed end. 4.The accessory attachment assembly of claim 2, wherein the fastenerengaging portion has an upper second channel located adjacent to thefirst channel, the second channel having a width that is greater thanthe first channel.
 5. The accessory attachment assembly of claim 4,wherein the second channel is a fastener head receiving channel.
 6. Theaccessory attachment assembly of claim 2, wherein the strap holdingportion comprises at least one strap slot configured to receive a strapthrough the strap slot, the strap slot adjacent to the first channel. 7.The accessory attachment assembly of claim 2, wherein the strap holdingportion comprises at least two strap slots configured to receive a strapthrough the strap slots, the strap slots located on opposite sides ofthe first channel.
 8. The accessory attachment assembly of claim 4,wherein the strap holding portion comprises at least two strap slotsconfigured to receive a strap, the strap slots located on opposite sidesof the second channel.
 9. The accessory attachment assembly of claim 7,wherein the first channel is configured to be located under a head of afastener, the second channel is configured to engage at least a portionof the head of a fastener, and wherein the first and second channels areslide channels configured to slidably receive a fastener.
 10. Anaccessory attachment assembly for a helmet, comprising: at least onemandible bracket configured to connect a mandible to a helmet; at leastone strap connected to the mandible bracket and configured to extendfrom the mandible bracket to a rear portion of a helmet; at least onestrap guide having a strap engaging portion connected to the strap alonga length of the strap, and a fastener engaging portion configured toconnect to a fastener attached to a helmet.
 11. The accessory attachmentassembly of claim 10, comprising first and second strap connectorsconfigured to connect at a rear of a helmet; the at least one mandiblebracket comprises first and second mandible brackets configured toconnect a mandible to a helmet, and wherein the at least one strapcomprises first and second straps, the first strap connected to thefirst mandible bracket at a first end of the first strap and the firststrap connector at an opposite second end of the first strap, the secondstrap connected to the second mandible bracket at a first end of thesecond strap and to the second strap connector at an opposite second endof the second strap; and wherein the at least one strap guide comprisesfirst and second strap guides, the first strap guide connected to thefirst strap between the first mandible bracket and the first strapconnector and configured to be secured by a fastener to a rear portionof a helmet, the second strap guide connected to the second strapbetween the second mandible bracket and the second strap connector andconfigured to be secured by a fastener to a rear portion of a helmet.12. The accessory attachment assembly of claim 10, comprising a mandibleconfigured to be positioned about a user's mandibular region, themandible attached to the mandible bracket.
 13. The accessory attachmentassembly of claim 10, comprising a mandible mount configured to beattached about a front opening of a helmet, the mandible bracketconnected to the front mount.
 14. The accessory attachment assembly ofclaim 13, wherein the front mount comprises a mandible mounting channel,the mandible bracket has a pin configured to be received in the mountingchannel to provide a pivotable connection of the mandible to the helmet.15. The accessory attachment assembly of claim 13, wherein the mandiblebracket is pivotably connected to the mandible mount.
 16. The accessoryattachment assembly of claim 11, comprising a mandible configured to bepositioned about a user's mandibular region, the first and secondmandible brackets attached to opposite sides of the mandible; themandible has a deployed position and a raised position, the strapshaving a connected position where the first strap connector is attachedto the second strap connector, and a released position; the straps whenin the connected position secure the mandible in the deployed position.17. The accessory attachment assembly of claim 10, wherein the fastenerengaging portion comprises a first channel having an open end opposite aclosed end; and the strap holding portion comprises at least two strapslots configured to receive a strap, the strap slots located on oppositesides of the first channel.
 18. A method of securing a face protector toa helmet, comprising : connecting a face protector about a front portionof the helmet by face protector brackets; bringing straps connected tothe face protector from opposite sides of the face protector to the rearof the helmet; sliding each of one or more strap guides onto a fastenerattached to the helmet, each of the one or more strap guides beingattached to one of the straps; and connecting the straps together at arear of the helmet.
 19. The method of claim 18, wherein the act ofconnecting is performed before the step of sliding.
 20. The method ofclaim 18, wherein the act of sliding comprises the step of sliding achannel of the strap guide between the head of the fastener and thesurface of the helmet until the fastener is placed between at least onelocking nub of the channel and the end of the channel.
 21. The method ofclaim 18 wherein the act of sliding comprises sliding each of the one ormore strap guides horizontally onto a fastener attached to the helmet.22. An accessory attachment assembly for a helmet, comprising: at leastone strap guide configured to connect a strap with a helmet; the strapguide having one of a fastener and a fastener engaging portion forreleasably receiving the other of a fastener and a fastener engagingportion secured to a portion of a helmet, the strap guide further havinga strap holding portion configured to hold a strap relative to theguide.
 23. An accessory attachment assembly for a helmet, comprising: atleast one mandible bracket configured to connect a mandible to a helmet;at least one strap connected to the mandible bracket and configured toextend from the mandible bracket to a rear portion of a helmet; at leastone strap guide having a strap engaging portion connected to the strapalong a length of the strap, and a fastener or a fastener engagingportion configured to connect to the other of a fastener or a fastenerengaging portion that is attached to a helmet.
 24. A method of securinga face protector to a helmet, comprising : connecting a face protectorabout a front portion of the helmet by face protector brackets; bringingstraps connected to the face protector from opposite sides of the faceprotector to the rear of the helmet; sliding each of one or more strapguides onto a fastener or fastener engaging portion attached to thehelmet, each of the one or more strap guides being attached to one ofthe straps; and connecting the straps together.
 25. The method of claim24, wherein connecting the strap together comprises connecting thestraps together at a rear of the helmet.
 26. A method comprising:disconnecting a connector which is connecting two strap portions of anaccessory-securing strap that is arranged to be mounted to a helmet;exerting a force on an accessory that is being secured by the straparrangement; and through the exertion of force on the accessory,disengaging at least one strap guide from the helmet, the strap guideholding a strap portion of the two strap portions.
 27. The method ofclaim 26, wherein exerting a force on the accessory pulls on each of thetwo strap portions, which each in turn pull a respective strap guide offof an associated engaging portion that is attached to the helmet. 28.The method of claim 27, wherein the two strap portions are arrangedhorizontally on the helmet when the strap guides are engaged with thehelmet.
 29. An accessory attachment assembly for a helmet, comprising: astrap to secure an accessory to a helmet; a first strap guide holdingthe strap relative to the first strap guide, the first strap guideincluding a first engaging portion to engage with a second engagingportion which is connected to the helmet, wherein when the first strapguide is attached to the helmet through the engagement of the first andsecond engaging portions, the assembly is constructed and arranged suchthat a force on the strap along a lengthwise direction of the strap andmore than a threshold force disengages the first engaging portion fromthe second engaging portion.
 30. The accessory attachment assembly as inclaim 29, wherein the strap includes a first strap portion and a secondstrap portion, and the assembly further comprises a connector to connectthe first and second strap portions together.
 31. The accessoryattachment assembly as in claim 30, wherein the first strap guide holdsthe first strap portion relative to the first strap guide, and furthercomprising a second strap guide which holds the second strap portionrelative to the first strap guide, the second strap guide including athird engaging portion to engage with a fourth engaging portion which isconnected to the helmet, wherein when the second strap guide is attachedto the helmet through the engagement of the third and fourth engagingportions; wherein the assembly is constructed and arranged such that aforce on the strap along a lengthwise direction of the strap and morethan a threshold force disengages the third engaging portion from thefourth engaging portion.
 32. The accessory attachment assembly as inclaim 31, wherein the first engaging portion includes a channel havingan open end, and the second engaging portion includes a fasteningelement attached to the helmet.